Method of assembling a steam iron base



July 12, 1966 N. E. LOOMIS 3,260,005

METHOD OF ASSEMBLING A STEAM IRON BASE Filed June 2, 1965 INVENT ORNELSON Elem/us ATTORNEY United States Patent 3 260,005 METHOD OFASSEMBiLING A STEAM IRON BASE Nelson E. Loomis, Colebrook, Conn,assiguor to Sou- Clrief Electrics, Inc., Wiusted, C0nn., a corporationof Connecticut Filed June 2, 1965, Ser. No. 460,757 3 Claims. (Cl.38-77) This invention relates generally to steam irons, and moreparticularly, to a steam iron base and method of assembling the variouscomponents thereof.

Smoothing irons generally comprise an electrically heated soleplatehaving a smoothing surface, and include an electrical heating elementusually of the rod type which is most often imbedded in the uppersurface of the soleplate for heating the smoothing surface. In an ironof the steam type the heating element also serves to supply thenecessary heat to a boiler or chamber for the generation of steamtherein. Irons of the steam generating type are extremely popular at thepresent time, by far the vast majority of all irons now being madefalling into this category. The present arrangement provides a novelconstruction of the various components forming the steam generatingmeans in combination with a soleplate, which components are assembled ina novel manner leading to ready joining of a mini-mum number ofcomponents which are assembled in a positive manner involving only ashort period of time and therefore minimum labor and expense.

Many of the electric irons with steam pressing features of the typeindicated above, which are known in the art, incorporate a plurality ofcomplicated and expensive to produce components which firstly, are ofdelicate or precision construction and secondly, require an intricatesystem of assembly thereby leading to an expensive construction makingit difficult to favorably compete on the present market. One of theprimary drawbacks in the construction of a steam iron has 'been theformation of calcareous deposits which result from the evaporation ofcommon tap water as most usually used in irons of this type. Amanufacturer hesitates to recommend exclusive use of distilled andsoftened water in his product in view of the implied burden placed uponthe purchaser; however, in many constructions the use of tap Water ineven a short period of time will build up calcareous deposits within thesteam generating chamber particularly immediately beneath the point ofentry of water from the water reservoir, these deposits eventuallyspreading towards the outlet ports formed through the soleplate andtending to clog these ports.

Another important feature which must be considered in the constructionof a steam iron is the provision of complete conversion of all water fedinto the steam generating chamber into steam and means must be providedfor insuring this complete conversion of all such water to steam withoutthe likelihood of any water being transmitted through the outlet portswhich it will be understood could cause staining, particularly whenironing certain synthetic fabrics.

Accordingly, one of the objects of the present invention is to provide asteam iron base including a novel arrangement of components constructedto provide more efficient generation of the steam.

"Patented July 12, 1966 Another object of the present invention is toprovide a steam iron base including improved means for insuring completeconversion of all water into steam thereby precluding any sputter orissuance of droplets of water from the outlet ports in the soleplate ofthe iron.

A further object of the present invention is to provide a steam ironbase including a plurality of components which are of a constructionproviding for ready assembly thereof in a positive manner.

Still another object of the present invention is to provide a method ofassembling the various components of a steam iron base in a positivemanner and with a minimum amount of labor involved.

With these and other objects in view, which more readily appear as thenature of the invention is better understood, the invention consists inthe novel construction, combination and arrangement of parts as well asa unique method of assembly thereof, both of which are hereinafter morefully described, illustrated and claimed.

A preferred and practical embodiment of the present invention is shownin the accompanying drawing in which:

FIGURE 1 is an exploded perspective view of the various componentsforming the present invention.

FIGURE 2 is a perspective view illustrating a plurality of thecomponents of the present invention in an assembled position.

FIGURE 3 is a transverse sectional view taken along the line 3--'3 ofFIGURE 2.

Similar reference characters designate cor-responding parts throughoutthe several views of the drawings.

Referring now to the drawing, particularly FIGURE 1, it will be seenthat the present invention comprises a plurality of components which areconstructed in a manner to provide for their assembly in a mating oroverlying relationship to provide an integral steam generating systemfor a steam iron base. The soleplate 10 may be formed of a conventionalcomposition such as aluminum or an aluminum alloy in order to obtain thefeature of a material having a high heat conductivity in combinationwith the properties of being of light weight and presenting a pleasingbright appearance. As in the usual manner of construction, the uppersurface 11 as well as the lower smoothing surface 12 are perfectly thatand a plu rality of outlet ports 13 are drilled through the soleplateadjacent the periphery thereof from the vicinity of the medial portionof the soleplate to a point adjacent the toe 14 thereof. As shown mostclearly in FIGURES '1 and '3, each of the ports 13 are countersunk as at14a on the smoothing surface 12 and are punched upwardly to provide aprotuberance 15 above the top surface 11. An important feature of thepresent soleplate 10 is the provision of at least a pair of upstandingorientation pins 16, '16 upon the top surface 11, which pins arepreferably disposed between the arrangement of outlet ports '13 adjacentthe two side edges of the soleplate and are of a diameter greater thanthe diameter of said ports for reasons which will become clearhereinafter.

Adapted to be disposed upon the top surface 11 of the soleplate 10between the protuberances 13 is a fiat locator plate 17 having a pair ofpin openings 18, 18 forming a close fit with the upstanding pins 16, 16.The curved peripheral edge 19 of the locator plate 17 is constructed sothat when the plate 17 is disposed upon the top surface 11 of thesoleplate with the pins 16 passing through the openings 18, the edge 19will be equispaced throughout its length from each of the immediatelyadjacent protuberances formed in the soleplate. Adapted to be disposedwithin this aforementioned space is a heating element, generallydesignated 20, which is of the rod type and comprises an outer casing 21of high heat conductivity and within which is disposed a resistanceheating wire 22 further isolated from contact with the casing 21 bymeans of suitable insulating material 23 having the property of beingboth highly dielectric as well as a good conductor of heat. As will bemost clearly seen in FIG- URE 3, the casing 21 of the heating element29' is of semicircular configuration when viewed in cross sectionthereby presenting a relatively large heat transfer area on its bottomsurface which is perfectly flat. After the locator plate 17 has beenmounted upon the top surface 11 of the soleplate 10, the heating element24 is lowered into position and disposed within the space between theperipheral edge 19 of the plate 17 and the protuberances 15 with thebottom surface 24 of the casing 21 flushly fitting upon the exposed topsurface 11 formed therebetween. At this point, the three components thusassembled, are united as an integral unit by welding or brazing thethree elements together, using any suitable material having the propertyof high heat conductivity. As thus assembled, the steam iron base willappear as in FIGURE 2. At this point, a drill is passed through thecenter of the previously formed countersinks 25 disposed beneath theorientation pins 16 in order to provide the additional outlet ports 26leading upward from the smoothing surface 12 through the locator plate17 as will be most clearly seen in FIGURE 3.

From the foregoing it will be unders-ood that the three elements, namelythe line of protuberances 15, the heating element and the locator plateare all of generally U shape and arranged to provide a close mating fitwhen assembled as shown in FIGURE 2.

A steam generating chamber 27 is formed above the forward portion of theassembly illustrated in FIGURE 2 by means of a steam generating chambercover 28 which may be constructed of any suitable metallic compositionand is stamped or otherwise shaped so that when fitted above theassembled soleplate, heating element and locator plate provides achamber 27 overlying all of the outlet ports 13 as well as the outletports 26. The entire periphery of the chamber cover 28 is provided withan outwardly extending horizontal flange. The sides and forward portionof the cover include a soleplate flange 29 While the rear of the coveris provided with a locator plate flange 30 as will be most clearly seenin FIGURE 1. Between the locator plate flange 30 and the rear of the twoside portions of the soleplate flange 29' are disposed two heatingelement flanges 31. For reasons which will become obvious the heatingelement flanges 31 are curved while the soleplate and locator plateflanges 29 and 36 respectively are planar. As will be seen in FIGURE 3,the locator plate flange 30 is disposed at a higher elevation than the:soleplate flange 29, the distance between these two planes beingsubstantially the thickness of the locator plate 17. The chamber cover28 is retained in the posi tion shown in FIGURE 3 by means of a studbolt 32 is threaded through a tapped opening in the locator plate, thechamber cover being securely retained in position by means of a suitablenut 33. Prior to the assembly of the steam generating chamber cover 28 alayer of suitable adhesive sealant material is deposited throughout thecoextensive areas of the flanges 29, 3t) and 31 such that when the coveris secured in position by means of the stud 32 and nut 33, a steam orair-tight generating chamber 27 will be formed within the cover, itbeing understood that the heating element flanges 31 are curved toprovide a mating fit about the curved portions of the heating elementcasing 21.

Water, for conversion into steam, is admitted into the steam generatingchamber 27 through an entry passage 34 formed in the top surface of thechamber cover 28 above the forward portion of the locator plate 17. Thelocator plate 17 includes a cut-out portion defined by a water receivingchannel 35 which in the present embodiment as herein illustrated isY-shaped with one leg of the channel disposed immediately beneath thewater entry passage 34 formed in the steam generating chamber cover 23.With the locator plate 17 in its assembled relationship as illustratedin FIGURE 2 it will be seen that an enclosed flash area 36 will beformed upon the top surface 11 of the soleplate. In this manner, aswater is metered by any suitable valve means (not shown) adapted to bedisposed through the entry passage 34, this water .will fall by gravity,as the iron is being used, within the confines of the flash area 36formed by the leg of the channel 35 to make direct contact with the topsurface 11 of the soleplate Within this flash area. It will thus be seenthat since both the soleplate 1% as well as the sides of the locatorplate 17 forming the channel 35 will be heated by means of the heatingelement 20, the water entering the flash area 36 will be immediatelyconverted to steam and the usual agitation of droplets of water fallinginto the flash area 36 will be minimized due to the height of the waterreceiving channel 35 to ensure minimum sputtering and completeconversion of the water to steam. As the steam is generated Within theflash area 36, it rises to fill the steam generating chamber 27 and issubsequently directed to the ports 13 and 26 and thence emerges from thebottom smoothing surface 12 of the so-leplate.

Any suitable means may be provided for maintaining a supply of waterintended to be metered through the entry passage 34 0f the chamber cover28. As illustrated in FIGURE 1 a reservoir or tank 37 having top, bottomand side walls is adapted to be fitted above the generating chambercover 28 and includes (not shown) a bottom opening adapted to beattached in any suitable fluid type manner above the entry passage 34 ofthe chamber cover 28.

To assist in the subsequent assembly of an outer iron cover (not shown),each side of the soleplate flange 29 of the chamber cover 28 may beprovided with an upstanding positioning ear 38 as shown in FIGURE 1,which ears project upwardly from the outer periphery of the flange 29.In this manner it will be understood that following the assembly of allof the components illustrated in FIGURE 1 together with any otherattendant structure, the outermost iron cover may be lowered over thisassembly and will be guided into position adjacent the outer surfaces ofthese two positioning ears 38.

It is to be understood that the invention is not limited to the specificfeatures shown, but that the means of construction herein disclosedcomprise the preferred form of several modes of putting the inventioninto effect and the invent-ion will therefore be understood in any ofits forms or modifications within the legitimate and valid scope of theappended claims.

I claim:

1. In a method of assembling a steam iron, the steps of; placing alocator plate having openings therein upon a soleplate provided with aplurality of outlet ports and upstanding integral orientation pins withsaid openings registering with said orientation pins, said locator platehaving a peripheral surface which when positioned by said orientationpins will be equispaced throughout its length from said outlet ports;placing a heating element on said s-oleplate within the space betweensaid locator plate and outlet ports; uniting said locator plate andheating element to; said soleplate; attaching a cover over said unitedlocator plate and heating element With said cover providing a commongenerating chamber enclosing said locator plate openings and saids-oleplate outlet ports;

5 6 sealing the periphery of said coverto said soleplate, heat-References Cited by the Examiner ing element and locator plate tomaintain said chamber UNITED STATES PATENTS fl 'd-t' ht; d t h t rv b "dan mg a w er me a Sal 2,499,184 2/1950 Flnlayson 3s 77 2,774,156 12/1956Parr 38-77 2. The method according to claim 1, including, form- 5 ing awater-receiving channel in said locator plate prior E233 et a1 t1}, 'dltit a lit. 1, 1

O p ammo Sal Oca or P a p S31 50 P a 6 3,165,844 1/1965 Sw anke 38 77 3.The method according to claim 1, including, forming outlet port-sthrough said orientation pins by drilling theret'hrough after assemblyof said locator plate upon 10 JORDAN FRANKLIN Prlmary Examiner saidsoleplate. PATRICK D. LAWSON, Examiner.

1. IN A METHOD OF ASSEMBLING A STEAM IRON, THE STEPS OF; PLACING ALOCATOR PLATE HAVING OPENINGS THEREIN UPON A SOLEPLATE PROVIDED WITH APLURALITY OF OUTLET PORTS AND UPSTANDING INTEGRAL ORIENTATION PINS, WITHSAID OPENINGS REGISTERING WITH SAID ORIENTATION PINS, SAID LOCATOR PLATEHAVING A PERIPHERAL SURFACE WHICH WHEN POSITIONED BY SAID ORIENTATIONPINS WILL BE EQUISPACED THROUGHOUT ITS LENGTH FROM SAID OUTLET PORTS;PLACING A HEATING ELEMENT ON SAID SOLEPLATE WITHIN THE SPACE BETWEENSAID LOCATOR PLATE AND OUTLET PORTS; UNITING SAID LOCATOR PLATE ANDHEATING ELEMENT TO SAID SOLEPLATE; ATTACHING A COVER OVER SAID UNITEDLOCATOR PLATE AND HEATING ELEMENT WITH SAID COVER PROVIDING A COMMONGENERATING CHAMBER ENCLOSING SAID LOCATOR PLATE OPENINGS AND SAIDSOLEPLATE OUTLET PORTS; SEALING THE PERIPHERY OF SAID COVER TO SAIDSOLEPLATE, HEATING ELEMENT AND LOCATOR PLATE TO MAINTAIN SAID CHAMBERFLUID-TIGHT; AND ATTACHING A WATER RESERVOIR ABOVE SAID COVER.